Fiber blends for dual hazard and comfort properties

ABSTRACT

Fiber blends useful for garments with a balance of high thermal and comfort properties are disclosed. The fiber blends comprise a FR fiber component, a comfort fiber component, a structural fiber component, and an optional antistatic fiber. Yarns, fabrics, and garments comprising the fiber blends are also disclosed. Such garments are particularly useful for occupations requiring high thermal properties, such as oil and gas workers, fire fighters, utility workers, and military personnel, without compromising comfort of the wearers by maintaining breathability and moisture management properties of the fabric.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application Ser.No. 61/620,417, filed Apr. 4, 2012 and titled “Fiber Blends for DualHazard and Comfort Properties,” the entirety of which is incorporatedherein by reference.

FIELD OF THE INVENTION

The present invention generally relates to fiber blends. Moreparticularly, the invention relates to fiber blends used for a balanceof high thermal and comfort properties and to the yarns, fabrics, andgarments made from the fiber blends.

BACKGROUND

Flame-resistant fabrics (also variously referred to as “fire-resistant,”“flame-retardant,” and “fire-retardant” fabrics) are fabrics that, onceignited, tend not to sustain a flame when the source of ignition isremoved. Considerable research has been directed toward the developmentand improvement of flame-resistant fabrics for use in various products,including clothing and bedding. Flame-resistant clothing is often wornby workers involved in activities such as industrial manufacturing andprocessing (such as oil, gas, and steel industries), fire-fighting,electrical utility work, military work, and other endeavors that entaila significant risk of being exposed to open flame, flash fire, momentaryelectrical arcs, and/or molten metal splash. Non-flame resistant workclothes can ignite and will continue to burn even after the source ofignition has been removed. Untreated natural fabrics will continue toburn until the fabric is totally consumed and non-flame resistantsynthetic fabrics will burn with melting and dripping causing severecontact burns to the skin. The majority of severe and fatal burninjuries are due to the individual's clothing igniting and continuing toburn, not by the exposure itself. Abrasion resistance of protectivefabrics is also important, as garments which have developed failuressuch as holes and rips can compromise the protective properties of thefabric.

Flame-resistant fabrics include both fabrics that are treated to beflame-resistant as well as flame-resistant fabrics made from inherentlyflame-resistant fibers. The former types of fabrics are not themselvesflame-resistant, but are made flame-resistant by applying to the fabrica chemical composition that renders the fabric resistant to flame. Thesetypes of fabrics are susceptible to losing their flame-resistance withrepeated laundering because the flame-resistant composition tends towash out. In contrast, inherently flame-resistant fabrics do not sufferfrom this drawback because they are made from fibers that are themselvesflame-resistant. The use of flame resistant clothing provides thermalprotection at the exposure area. The level of protection typically restsin the fabric weight and composition. After the source of the ignitionis removed, flame resistant garments will self-extinguish, limiting thebody burn percentage.

Flame-resistant fabrics often contain a low percentage of natural fibersand have limited comfort properties such as adsorption of water.Flame-resistant fabrics are most often worn in work environments andcomfort, including adsorption of sweat from the skin, is an importantperformance factor, especially in extreme conditions such asfirefighting. Combining some percentage of natural hydrophilic fiberswith FR fibers may provide some improvement in comfort and moisturewicking, however this typically comes at a loss of FR performanceproperties. Most FR fibers, including modacrylic fibers, are hydrophobicand do not provide high comfort performance.

Various types of inherently flame-resistant (FR) fibers have beendeveloped, including modacrylic fibers (e.g., modacrylic fibers soldunder the PROTEX name from Kaneka Corporation of Osaka, Japan, andTairylan sold by Formosa Plastics of Taiwan). Acrylic FR fibers soldunder the name PyroTex, (Hamburg, Germany), aramid fibers (e.g.,meta-aramid fibers sold under the NOMEX name and para-aramid fibers soldunder the KEVLAR name, both from E. I. Du Pont de Nemours and Company ofWilmington, Del.), FR rayon fibers, oxidized polyacrylonitrile fibers,and others. It is common to blend one or more types of FR staple fiberswith one or more other types of non-FR staple fibers to produce a fiberblend from which yarn is spun, the yarn then being knitted or woven intofabrics for various applications. In such a fiber blend, the FR fibersrender the blend flame-resistant even though some fibers in the blendmay themselves be non-FR fibers, because in the case of antimony andhalogen filled fibers when the FR fibers are exposed to heat and flamethey release non-combustible gases that tend to displace oxygen andthereby extinguish any flame. In the case of non-filled FR fibers thehigh percentage of FR fibers form char, or exhibit other characteristicswhich provide wearer protection.

In addition to the above-noted performance specifications of fabrics,other properties are also important if a fabric is to be practical andcommercially viable, particularly for clothing. For instance, the fabricshould be durable under repeated industrial launderings and should havegood abrasion-resistance. Furthermore, the fabric should be comfortableto wear. Unfortunately, many of the FR blends are not comfortable undertypical environmental conditions. In such cases, wearers tend to be lesslikely to be compliant and thereby decreasing the probability that thewearer will continue to use the garment as intended. Thus, it isbeneficial if an FR fabric exhibits good moisture management properties,i.e., ability to wick away sweat and dry quickly so that the wearer doesnot become overheated or chilled, and/or the fabric does not irritatethe wearer's skin.

Selection of a fiber blends to meet a plurality of the requirements asdescribed, while being affordable is a constant challenge. Some fiber,such as (FR) fiber and especially inherently (FR) fibers that arethermally shrink resistant, as defined herein, are relatively expensive,and incorporating a high percentage of these fibers into a yarn andfabric may be cost prohibitive for many applications.

Woven FR fabrics are well suited for many of the FR test protocols,including NFPA 2112 and especially the thermal shrinkage tests. Wovenfabrics are relatively tight, having little void volume, between yarns,therein reducing the propensity to thermally shrink. Other types offabric structures, such as knits, may be more comfortable to wear, asthey typically have higher porosities, however they typically may notmeet the thermal shrinkage requirements. The yarns in a knit fabric arelooped and therefore not as restrained as yarns in a conventional wovenfabric and therefore can shrink more.

There exists a need for a fiber blend and fabric made therefrom that isnot only electric arc protective and flame-resistant but that is alsothermally shrink resistant, meeting the thermal shrinkage resistancerequirements of NFPA 2112, while also providing superior moisturemanagement properties and strength properties to ensure wearercompliance. The fiber blends, fabrics, and garments of the presentinvention are directed toward these, as well as other, important ends.

SUMMARY OF THE INVENTION

The invention relates generally to fiber blends and to fabrics andgarments comprising the fiber blends that achieve a balance of highthermal properties, including flame resistance and thermal shrinkageresistance, as well as moisture management properties to provide bothprotection and comfort to the wearer. In one embodiment the fiber andfabrics made therefrom are dual hazard materials, meeting both NFPA 2112requirements and having an arc rating of at least 8 cal/cm² min asdescribed herein. In yet another embodiment, the fabric made from afiber blend described herein, is a dual hazard fabric and also has aninitial weight gain of at least 40% and/or a WRR of at least 0.35%/minafter 10 wash cycles, as described herein. An exemplary fiber blenddescribed herein comprises some weight percent of comfort fiber thatprovides for improved moisture management, such as wicking sweat awayfrom a wearer's skin. In addition, the comfort fiber described hereinmay comprise a natural fiber that is soft and increases comfort whenworn directly against the skin.

Accordingly, in one embodiment, the invention is directed to fiberblends and fabrics made therefrom, comprising a blend of FR fibers,comprising a first FR modacrylic fiber that is hydrophobic and a secondacrylic FR fiber that is thermally shrink resistant and may behydrophilic. A fiber blend may comprise any suitable percent by weightof the blend of FR fibers including, but not limited to, more than about30%, more than about 40%, more than about 50%, more than about 60%, morethan about 70%, no more than about 80%, or any range between andincluding the weight percentages provided. In one embodiment the acrylicFR fiber is hydrophilic, providing improved moisture wicking performanceand may also be dye accepting. The thermally shrink resistant acrylic FRfiber component of the FR fiber blend is relatively expensive comparedto the FR modacrylic fiber component, and therefore, optimizing and orminimizing the concentration of the acrylic FR fiber to whilemaintaining a surprising combination of properties including meeting thedual hazard requirement and/or meeting the thermal shrink resistancerequirement. It has been found that a FR fiber blend and fabric madetherefrom can meet the dual hazard requirements as well as the thermalshrinkage requirements with as little as 10% of the acrylic FR fiber.Any suitable weight percentage, based on the total fiber blend weight,of the acrylic FR fiber may be incorporated into the fiber blendincluding, but not limited to, more than about 10%, more than about 15%more than about 20%, more than about 25%, more than about 30%, and anyrange between and including the provided weight percentages. The acrylicFR fiber component is expensive and it is therefore preferred toincorporate by total fiber weight, no more than about 30%, or no morethan about 25%.

A fiber blend described herein may incorporate the FR fiber blend, aswell as other fiber components, such as 10-35%, by weight, based on thetotal weight of the fiber blend, of a comfort fiber component comprisingat least one material selected from the group consisting of cotton,cellulose, cellulose derivatives, wool, and combinations thereof; and5-25%, by weight, based on the total weight of the fiber blend, of atleast one structural fiber component comprising at least one materialselected from the group consisting of aramid fiber, melamine fiber,nylon fiber, structural carbon fiber, polyacrylonitrile fibers andcombinations thereof. The fiber blend described herein my furthercomprise 0.1 to 3% by weight, or more preferably 1% to 3%, based on thetotal weight of the fiber blend, of at least one antistatic fiber. Inaddition, the fiber blend, yarns, and fabrics described herein mayfurther comprise an antimicrobial component, such as an antimicrobialfiber or coating.

In another embodiment, the invention is directed to fiber blendscomprising: 30-80%, by weight, of a FR fiber component comprising afirst FR fiber component, comprising at least one fiber selected fromthe group consisting of modacrylic, FR acrylic, acrylic derivatives,fluoropolymer, polybenzimidazole (PBI), and copolymers thereof, andcombinations thereof that is hydropobic, and a second thermally shrinkresistant FR fiber that is at a concentration of at least 10% by weightof the total fiber blend; 10-35%, by weight, based on the total weightof the fiber blend, of a comfort fiber component comprising at least onematerial selected from the group consisting of cotton, cellulose,lyocell, cellulose derivatives, wool, and combinations thereof and5-25%, by weight, based on the total weight of the fiber blend, of atleast one structural fiber component comprising at least one materialselected from the group consisting of aramid fiber, melamine fiber,nylon fiber, structural carbon fiber, polyacrylonitrile fibers (PAN) andcombinations thereof. The fiber blend described herein my furthercomprise 0.1 to 3% by weight, based on the total weight of the fiberblend, of at least one antistatic fiber.

In some embodiments, the FR fiber component comprises, or consistsessentially of inherently FR fiber. In one embodiment at least about 20%by weight of the FR fiber component comprises or consists essentially ofhydrophobic FR fiber. In yet another embodiment at least about 10% ofthe FR fiber component is hydrophilic FR fiber. In some embodiments, thethermally shrink resistant FR fiber comprises or consists essentially ofinherently FR fiber. In yet other embodiments, the thermally shrinkresistant FR fiber component comprises or consists essentially ofhydrophilic fiber. In some embodiments the thermally shrink resistant FRfiber is a dye accepting fiber. In some embodiments the thermally shrinkresistant FR fiber is a high LOI fiber having a LOI value of at least 38as described herein.

In some embodiments the FR fiber comprises at least 10% by weight,thermally shrink resistant FR fiber. In another embodiments the FR fibercomprises at least 20% by weight, thermally shrink resistant FR fiber.

In some embodiments, the fiber blend as described herein, is a dualhazard fiber blend, whereby fabric made therefrom meets NFPA 2112requirement and has an arc rating of at least 8 cal/cm2. Furthermore,the dual hazard fabric may have an initial water weight gain of at least40% and/or a WRR of at least 35%/min after 10 wash cycles.

In some embodiments, the invention is directed to yarns comprising thefiber blends described herein. In other embodiments, the invention isdirected to fabrics comprising the fiber blends described herein. In yetother embodiments, the invention is directed to garments, especiallyouterwear, comprising the fabric formed from the fiber blends describedherein.

The summary of the invention is provided as a general introduction tosome of the embodiments of the invention, and is not intended to belimiting. Additional example embodiments including variations andalternative configurations of the invention are provided herein.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a furtherunderstanding of the invention and are incorporated in and constitute apart of this specification, illustrate embodiments of the invention andtogether with the description serve to explain principles of theinvention.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

FIG. 1 is a graph showing the fiber blend concentrations of Fiber Blend1, an exemplary embodiment described herein.

FIG. 2 is a graph showing the fiber blend concentrations of Fiber Blend2, an exemplary embodiment described herein.

FIG. 3 is a graph showing the fiber blend concentrations of Fiber Blend3, an exemplary embodiment described herein.

FIG. 4 is a graph showing the fiber blend concentrations of Fiber Blend4, an exemplary embodiment described herein.

FIG. 5 is a graph showing the fiber blend concentrations of acomparative example.

FIG. 6 is a top view of woven fabric in a 2×1 twill weave.

FIG. 7 is a top down view of a knit having looped yarns.

The figures represent an illustration of some of the embodiments of thepresent invention and are not to be construed as limiting the scope ofthe invention in any manner. Further, the figures are not necessarily toscale, some features may be exaggerated to show details of particularcomponents. Therefore, specific structural and functional detailsdisclosed herein are not to be interpreted as limiting, but merely as arepresentative basis for teaching one skilled in the art to variouslyemploy the present invention.

As employed above and throughout the disclosure, the following terms,unless otherwise indicated, shall be understood to have the followingmeanings.

As used herein, the terms “comprises,” “comprising,” “includes,”“including,” “has,” “having” or any other variation thereof, areintended to cover a non-exclusive inclusion. For example, a process,method, article, or apparatus that comprises a list of elements is notnecessarily limited to only those elements but may include otherelements not expressly listed or inherent to such process, method,article, or apparatus. Also, use of “a” or “an” are employed to describeelements and components described herein. This is done merely forconvenience and to give a general sense of the scope of the invention.This description should be read to include one or at least one and thesingular also includes the plural unless it is obvious that it is meantotherwise.

As used herein with reference to fiber, yarn or fabric compositions, theterm “consisting essentially of” means that the fiber, yarn or fabric ismade primarily of a described component, such as a polymer, material orfiber type and may include small amounts, less than 5% by weight ofadditional treatments, coating or finishes.

As used herein with reference to fabric, the term “formed substantiallyof” means that the fabric includes at least 50% by weight, based on thetotal weight of the fabric, preferably at least 75% by weight, based onthe total weight of the fabric, and more preferably at least 95% byweight, based on the total weight of the fabric of a specific fiberblend or yarn composition.

As used herein, the term “modacrylic fiber” refers to a acrylicsynthetic fiber made from a polymer comprising primarily residues ofacrylonitrile, especially polymers that have between 35 to 85%acrylonitrile units, and which may be modified by other monomers.Modacrylic fibers are spun from an extensive range of copolymers ofacrylonitrile. The modacrylic fiber may contain the residues of othermonomers, including vinyl monomer, especially halogen-containing vinylmonomers, such as but not limited to vinyl chloride, vinylidenechloride, vinyl bromide, vinylidene bromide, and the like. The types ofmodacrylic fibers that can be produced within this broad category arecapable of wide variation in properties, depending on their composition.Acrylic derivative fibers, as used herein includes modacrylic fibers asdescribed herein and any fiber comprising acrylic monomer units,including acrylic FR fibers sold under the name PyroTex, (Hamburg,Germany). Some examples of commonly available modacrylics are PROTEX™,KANEKALON™, KANECARON™ by Kaneka Corporation. Modacrylic fibers haveexcellent fire retardancy performance combined with non-melt, non-dripand self-extinguishing properties. These are critically importantattributes in many working environments. If sufficiently hightemperatures are reached on exposure to fire or explosion, a garmentmade with the inventive fiber blends of the invention will carbonize byforming a protective charred barrier. This prevents propagation offlames, thereby protecting the wearer from severe burn injuries.Modacrylics have a high so-called LOI value as compared with otherfibers. The LOI represents the minimum oxygen concentration of an O₂/N₂mix required to sustain combustion of a material. The LOI is determinedby the ASTM Test D 2862-77. Modacrylics have an LOI value preferablybetween about 28 and 33 while conventional polyesters have a much lowervalue of about 20 to 22. A high LOI fiber or material, as definedherein, has an LOI of more than 38. For example, acrylic FR fiber,available from Pyrotex has an LOI greater than 40.

Some FR fiber are more environmentally friendly and do not containantimony or halogen compounds. In addition, most FR fibers have alimiting oxygen index LOI, greater than 25, and some FR fibers may becharacterized as being high LOI FR fibers, having an LOI of greater than38. A high LOI is preferred as it improves FR performance, including theperformance of fiber blends. Finally, some FR fibers are hydrophilicincluding Acrylic FR fiber sold under the name PyroTex. Hydrophilicfibers, including hydrophilic FR fibers are typically dye acceptingfibers.

As used herein, acrylic FR fiber, refers to a FR fiber that is thermallyshrink resistant, hydrophilic and in some embodiments has and LOIgreater than 38. In some embodiments an acrylic FR fiber is antimony andhalogen free, such as acrylic FR fiber available from Pyrotex.

As used herein, the term “fluoropolymer” refers to a fluorocarbon-basedpolymer with at least one, but preferably multiple, strongcarbon-fluorine bonds, including, but not limited to,polytetrafluoroethylene (PTFE), perfluoroalkoxy polymer (PFA), orfluorinated ethylene-propylene (FEP).

As used herein, the term “aramid fiber” refers to a manufactured fiberin which the fiber-forming substance is a long-chain synthetic polyamidein which at least 85% of the amide linkages, (—CO—NH—), are attacheddirectly to two aromatic rings, including, but not limited to,para-aramid (p-aramid) and meta-aramid (m-aramid). Examples ofpara-aramids include, but are not limited to, (poly(p-phenyleneterephthalamide), e.g., KEVLAR® (E.I. du Pont de Nemours and Company),TWARON® (Teijin Twaron BV), and TECHNORA by Teijin Company. KEVLAR is apara-aramid fiber having a very high tenacity of between 28 and 32grams/denier and outstanding heat resistance. Examples of meta-aramidsinclude, but are not limited to, (poly(m-phenylene isophthalamide), suchas NOMEX® (E.I. du Pont de Nemours and Company) and CONEX® (TeijinTwaron BV). Preferably, the structural fiber is p-aramid, microdenierp-aramid. Such structural fibers feature excellent thermal stability andare virtually non-flammable. These fibers have a very high resistance toheat and are resistant to melting, dripping and burning at a temperatureof at least 700° F. Moreover, their LOI value is preferably in the rangeof between about 28 and about 30.

As used herein, the term “melamine fiber” is a manufactured fiber inwhich the fiber-forming substance is a synthetic polymer composed of atleast 50% by weight of a crosslinked non-thermoplastic melamine polymerof melamine units joined by methylene and dimethylene ether linkages. Inthe polymerization reaction, methylol derivatives of melamine react witheach other to form a three-dimensional structure. This structure is thebasis for the fiber's heat stability, solvent resistance, and flameresistance.

As used herein, the term “antistatic fiber” or conductive refers to afiber that, when incorporated into a fabric or other material,eliminates or reduces static electricity. Suitable fibers include, butare not limited to, metal fibers (steel, copper or other metal),metal-plated polymeric fibers, and polymeric fibers incorporating carbonblack on the surface and/or in the interior of the fiber, such as thosedescribed in U.S. Pat. No. 3,803,453, U.S. Pat. No. 4,035,441, U.S. Pat.No. 4,107,129, and the like. Antistatic carbon fiber is a preferredantistatic fiber. One example of such conductive fiber is NEGASTAT®produced by E.I. du Pont de Nemours and Company, a carbon fibercomprising a carbon core of conductive carbon surrounded bynon-conductive polymer cover, either nylon or polyester. Another exampleis RESISTAT® made Shakespeare Conductive Fibers LLC, a fiber where thefine carbon particles are embossed on the surface of a nylon filament.The yarns of both such fibers are available in a denier of at least 40.By way of example, a steel wire is available under the names BEKINOX andBEKITEX from Bekaert S.A. in a diameter as small as 0.035 millimeter.Another antistatic fiber is the product X-static made by Noble FiberTechnologies, a nylon fiber coated with a metal (silver) layer. TheX-static fibers may be blended with other fibers, such as modacrylics,in the process of yarn spinning.

As used herein, the term “structural carbon fiber” refers to fibers ofabout 0.005-0.010 mm in diameter and formed primarily of carbon atoms.The carbon atoms are bonded together in microscopic crystals that aremore or less aligned parallel to the long axis of the fiber. Each carbonfilament is produced from a precursor polymer. Common precursor polymersinclude commonly rayon, polyacrylonitrile (PAN), and petroleum pitch.For synthetic polymers such as rayon or PAN, the precursor is first spuninto filaments, using chemical and mechanical processes to initiallyalign the polymer atoms in a way to enhance the final physicalproperties of the completed carbon fiber. After drawing or spinning, thepolymer fibers are then heated to drive off non-carbon atoms(carbonization), producing the final carbon fiber. Suitable structuralfibers are available from Zoltek, SGL Carbon, Fortafil, Sumitomo, andKureha Corporation.

As used herein, with reference to fibers, yarns and fabric madetherefrom, the term “thermally shrink resistant”, means that the saidfabrics meet the thermal shrinkage resistance requirements of NFPA2112-0.7 Ed, Section 8.4, and has less than 10% shrinkage according tothe test described herein.

Some specialty fibers are thermally shrink resistant, and whenincorporated into a fiber blend may provide enough thermal shrinkresistance to allow the yarn or fabric made therewith to meet thermalshrinkage requirements. For example, acrylic FR fiber available fromPyrotex has low thermal shrinkage properties, and when incorporated intothe fiber blend in a concentration of more than 10%, as shown herein, afabric made with the fiber blend meets the thermal shrinkagerequirements of NFPA 2112-0.7 Ed, Section 8.4.

Suitable thermally shrink resistant fibers include, but are not limitedto, acrylic FR fibers (e.g., PyroTex, Hamburg, Germany),polyacrylonitrile (PAN), aramid fibers (e.g., meta-aramid fibers soldunder the NOMEX name and para-aramid fibers sold under the KEVLAR name,both from E. I. Du Pont de Nemours and Company of Wilmington, Del.), andthe like FR Rayon, FR Cotton, Basofill etc. In some embodiments, athermally shrink resistant fiber may be hydrophilic and/or dyeaccepting, as used herein to mean that the fiber may accept a die tosubstantially and durably impart a color to the fiber. Durably impart acolor to the fiber means that the fiber will substantially retain thecolor after three or more wash cycles.

Many of the thermally shrink resistant fibers are hydrophobic and arenot dye accepting, such as polyacrylonitrile (PAN), and aramid fibers.Certain acrylic derivative fibers, such as acrylic FR fibers availablefrom PyroTex, are both thermally shrink resistant and can accept a dye.These fibers provide, when incorporated into the fiber blends describedherein, a unique combination of properties heretofore unachieved. Inparticular, yarns, fabric and garments incorporating thermally shrinkresistant fibers as described herein, may be constructed to meet “dualhazard” requirements and also thermal shrinkage resistance requirements.

As used herein, with reference to fibers, yarns and fabrics, the term“dual hazard” means the fiber, yarn, fabric or garment made therefrommeets the requirements of NFPA 2112 and has an arc rating of at least 8cal/cm²

As used herein, the term “basis weight” refers to a measure of theweight of a fabric per unit area. Typical units include ounces persquare yard and grams per square centimeter.

As used herein, the term “garment” refers to any article of clothing orclothing accessory worn by a person, including, but not limited toshirt, pants, underwear, outer wear, footwear, headwear, swimwear,belts, gloves, headbands, and wristbands.

As used herein, the term “linen” (when not in relation to thehydrophilic fiber) refers to any article used to cover a worker orseating equipment used by workers, including, but not limited to sheets,blankets, upholstery covering, vehicle upholstery covering, and mattresscovering.

As used herein, the term “intimate blend,” when used in conjunction witha yarn, refers to a statistically random mixture of the staple fibercomponents in the yarn.

Accordingly, in one embodiment, the invention is directed to fiberblends and fabrics made therefrom, comprising: 30-80%, by weight, of aFR fiber component comprising a first FR fiber component, comprising atleast one fiber selected from the group consisting of modacrylic,acrylic derivative, fluoropolymer, polybenzimidazole (PBI), andcopolymers thereof, and combinations thereof that is hydrophobic, and asecond thermally shrink resistant FR fiber that is at a concentration ofat least 10% by weight of the total fiber blend; 10-35%, by weight,based on the total weight of the fiber blend, of a comfort fibercomponent comprising at least one fiber selected from the groupconsisting of cellulose, cellulose derivatives, wool, and combinationsthereof; and 5-25%, by weight, based on the total weight of the fiberblend, of at least one structural fiber component comprising at leastone polymer selected from the group consisting of aramid fiber, melaminefiber, nylon fiber, structural carbon fiber, polyacrylonitrile fibers,and combinations thereof. The fiber blend described herein my furthercomprise 0.1 to 3% by weight, based on the total weight of the fiberblend, of at least one antistatic fiber.

In certain embodiments, when the fiber blend is formed into a fabricformed substantially of said fiber blend, the fabric provides protectionagainst second and third degree burns on less than about 35% of thewearer, when tested in accordance with the American Society for Testingand Materials Standard Test ASTM F 1930-2000. In preferred embodiments,fabric provides protection against second and third degree burns on lessthan about 25% of the wearer, when tested in accordance with theAmerican Society for Testing and Materials Standard Test ASTM F1930-2000. In more preferred embodiments, fabric provides protectionagainst second and third degree burns on less than about 15% of thewearer, when tested in accordance with the American Society for Testingand Materials Standard Test ASTM F 1930-2000, as provided in Table 11.

In certain embodiments, when the fiber blend is formed into a fabricformed substantially of said fiber blend, the fabric has a char lengthless than about 5 inches, preferably less than about 4 inches, whentested in accordance with the American Society for Testing and MaterialsStandard Test ASTM 6413, as provided in Table 9.

In certain embodiments, when the fiber blend is formed into a fabricformed substantially of said fiber blend, the fabric may have a heat anda thermal protective performance value of at least about 5 cal/cm² min,preferably at least about 5.7 cal/cm² min initially, and at least about6.7 cal/cm² min after 3 washing cycles, when tested in accordance withthe National Fire Prevention Association NFPA 1971 (without spacer), asprovided in Table 12.

In certain embodiments, the yarns comprising the fiber blends describedherein are constructed into a fabric that has a thermal shrinkage valueof less than about 10%, when tested in accordance with the National FirePrevention Association NFPA 2112. Section 8.4, as provided in Table 10.

In certain embodiments, when the fiber blend is formed into a fabricformed substantially of said fiber blend, the fabric may have a waterweight gain of at least 40% and/or a WRR after three was cycles of atleast 0.35%/min when tested according to AATCC MM TS-05, as provided inTable 7.

In certain embodiments, when the fiber blend is formed into a fabricformed substantially of said fiber blend, the fabric may have a wet anddry abrasion performance of 1500 and 4000 respectively when testedaccording to American Society for Testing and Materials Standard TestASTM D 1424, as provided in Table 8.

The FR fiber component of the fiber blend of the invention is present ata level of about 30-80%, by weight, based on the total weight of thefiber blend, wherein at least 10% of the FR fiber is a thermally shrinkresistant fiber, and comprises at least one polymer selected from thegroup consisting of modacrylic, fluoropolymer, polybenzimidazole (PBI),and copolymers thereof, and combinations thereof. The FR fiber maycomprise any suitable weight percent of the fiber blend, based on thetotal weight of the fiber blend including, but not limited to, greaterthan about 30%, greater than about 40% greater than about 50%, greaterthan about 60%, greater than about 65%, about 70% and any range betweenand including the weight percentages provided. The FR fiber component ofthe fiber blend may comprise any suitable weight percentage of athermally shrink resistant fiber including, but not limited to, greaterthan about 5%, greater than about 10% greater than about 15%, greaterthan about 20%, greater than about 30%, greater than about 40%, greaterthan about 50%, greater than about 60%, and any range between andincluding any of the weight percentages provided. The shrink resistantfiber is typically more expensive than conventional FR fiber, such asmodacrylic, and therefore it is preferred to optimize the concentrationof the shrink resistant fiber component to provide the dual hazardproperties while keeping cost of the fiber blend down. In an exemplaryembodiment, the fiber blend comprises 75 weight percent, FR componentcomprising 20 weight percent, based on the total fiber weight, of athermally shrink resistant fiber. In certain embodiments of the fiberblend, the FR fiber component is modacrylic or copolymer thereof. The FRfiber may be comprised of, or consist of an inherently FR fiber.

In other embodiments, a fluoropolymer fiber comprises a polymer selectedfrom the group consisting of polytetrafluoroethylene (PTFE),perfluoroalkoxy polymer (PFA), fluorinated ethylene-propylene (FEP), andmixtures thereof.

The comfort fiber component of the fiber blend of the invention ispresent at a level of about 10% to about 35%, by weight, based on thetotal weight of the fiber blend, and comprises at least one fiberselected from the group consisting of cellulose, cellulose derivatives(such as cotton, viscose, linen, rayon, fire-resistant rayon, or acombination thereof), wool, and combinations thereof. In one embodiment,the comfort fiber component comprises or consists essentially ofhydrophilic fiber. In another embodiment the comfort fiber componentcomprises or consists essentially of cellulose, or cellulose derivativefibers, as described herein. Any suitable weight percent, based on thetotal fiber weight, of the comfort fiber component may be incorporatedinto the fiber including, but not limited to, greater than about 10%,greater that about 15%, greater than about 20%, greater than about 30%,greater than about 35%, and any range between and including the weightpercentages provided. In other embodiments, the cellulose derivative iscotton, viscose, linen, rayon, or a combination thereof. A preferredcomfort fiber component is cotton or fire-resistant rayon, or acombination thereof.

The structural component of the fiber blend of the invention is presentat a level of about 5-25%, by weight, based on the total weight of thefiber blend. The structural fiber component comprises at least one fiberselected from the group consisting of aramid fiber, melamine fiber,nylon fiber, structural carbon fiber, polyacrylonitrile fibers andcombinations thereof; wherein said aramid fiber is present at a level ofat least about 5%, by weight, based on the total weight of the fiberblend. Any suitable weight percent, based on the total fiber weight, ofthe structural fiber component may be incorporated into the fiberincluding, but not limited to, greater than about 5%, greater that about10%, greater than about 15%, greater than about 20%, about 25% and anyrange between and including the weight percentages provided. In otherembodiments, the structural component is aramid fiber, such as m-aramidpolymer fiber or p-aramid polymer fiber. In certain embodiments, thearamid fiber is present at a level of about 5-15%, by weight, based onthe total weight of the fiber blend. In other embodiments, thestructural component is a combination of nylon fiber and aramid fiber,particularly p-aramid fiber. In certain other embodiments, thestructural component is a combination of nylon fiber and aramid fiber,particularly p-aramid fiber, where both components are preferablypresent at a level of about 10%, by weight, based on the total weight ofthe fiber blend.

In certain embodiments of the fiber blend, an optional antistatic fiberis present at a level of about 0.1-3%, by weight, based on the totalweight of the fiber blend. In certain embodiments, the antistatic fiberis an antistatic carbon fiber.

In certain embodiments of the fiber blend, the FR fiber component ismodacrylic or a copolymer thereof; the comfort fiber component iscellulose or a cellulose derivative, or a combinations thereof; and thestructural fiber component is aramid fiber, nylon fiber, or acombination thereof.

In certain embodiments of the fiber blend about 70% by weight, based onthe total weight of the fiber blend, is acrylic derivative FR fibercopolymers thereof; about 20%, by weight is cotton; about 10%, by weightis para-aramid fiber; and about 2%, by weight is antistatic carbonfiber.

In certain embodiments of the fiber blend about 75%, by weight, based onthe total weight of the fiber blend, is acrylic derivative FR fiber andcopolymers thereof; about 15%, by weight is cotton; and about 10%, byweight is para-aramid fiber.

In certain embodiments of the fiber blend, about 55% by weight of thefiber, based on the total weight of the fiber, is FR fiber component andcomprises modacrylic or a copolymer thereof, and about 20% by weight isthermally shrink resistant fiber; and about 15% by weight is comfortfiber component comprising cellulose or a cellulose derivative, or acombinations thereof; and about 10% by weight is structural fibercomponent comprising aramid fiber, nylon fiber, or a combinationthereof. In an exemplary embodiment, the thermally shrink resistantfiber is acrylic FR fiber.

In certain embodiments of the fiber blend, the FR fiber component is 55%by weight Protec modacrylic fiber, and 20% by weight PyroTex thermallyshrink resistant fiber, an acrylic derivative fiber; the comfort fibercomponent is Tencel G1 fiber; and the structural fiber component isaramid.

In another aspect, the invention is directed to yarns comprising thevarious fiber blends described herein, wherein said FR fiber component,said comfort fiber component, said structural fiber component, and saidoptional antistatic fiber are intimately blended. An intimate fiberblend may be formed into any suitable fabric, as described herein. In anexemplary embodiment, an intimate blend of fibers is formed into a wovenfabric. In another exemplary embodiment an intimate blend of fibers isformed into a knit fabric.

In another aspect, the invention is directed to fabrics formed from theyarns comprising the various blends described herein. The fabrics may beeither woven or knitted. In certain embodiments, the fabric has a basisweight of less than about 8.0 ounces/square yard (OPSY). In certainother embodiments, the fabric has a basis weight of less than about 6.0ounces/square yard (OPSY).

The fiber blend as described herein may formed into any suitable type offabric in including, but not limited to, non-wovens, such ashydroentangled, and wet-laid, and wovens including, twill weaves, denimweaves, and knits for example. In one embodiment, the fiber blenddescribed herein may be formed into a knit fabric that meets the dualhazard standards as described herein. As shown in FIG. 7, a fabrichaving a knit weave typically has more open area than a twill typeweave, as shown in FIG. 5. A knit fabric comprises looped yarns thatprovide a comfortable feel, however, this type of weave may be moresusceptible to high thermal shrinkage. Tighter weaves, such as thatshown in FIG. 6, however comprise yarns that are more tightly packed andtherefore typically perform better in thermal shrinkage tests, thanknits. In one embodiment, it is envisioned that the fiber blenddescribed herein may be formed into a knit fabric that meets thestandards of dual hazard, as described herein, and is thermally shrinkresistant as described herein.

In some embodiments, the fabric may be formed into a garment. In certainembodiments, the fabric forms at least one outer portion of the garmentbecause of the protection it provides. The fabric is useful in garmentssuch as outwear, including, but not limited to coats, coveralls,overalls, shirts, and pants, and is particularly useful in firefighterturnout coats. In other embodiments, the fabric is formed into agarment, such as an undershirt, in a single tubular design to eliminateor reduce the number of seams and failure points.

In other embodiments, linen may be formed from the fabric of theinvention.

The present invention is further defined in the following Examples, inwhich all parts and percentages are by weight, unless otherwise stated.It should be understood that these examples, while indicating preferredembodiments of the invention, are given by way of illustration only.From the above discussion and these examples, one skilled in the art canascertain the essential characteristics of this invention, and withoutdeparting from the spirit and scope thereof, can make various changesand modifications of the invention to adapt it to various usages andconditions

Certain exemplary embodiments of the present invention are describedherein and illustrated in the accompanying figures. The embodimentsdescribed are only for purposes of illustrating the present inventionand should not be interpreted as limiting the scope of the invention.Other embodiments of the invention, and certain modifications,combinations and improvements of the described embodiments, will occurto those skilled in the art and all such alternate embodiments,combinations, modifications, improvements are within the scope of thepresent invention.

It will be apparent to those skilled in the art that variousmodifications, combination and variations can be made in the presentinvention without departing from the spirit or scope of the invention.Specific embodiment, features and elements described herein may bemodified, and/or combined in any suitable manner. Thus, it is intendedthat the present invention cover the modifications, combination andvariations of this invention provided they come within the scope of theappended claims and their equivalents.

Examples

Initial screening tests on fiber blends were performed to determine howchanges in concentration of various fibers effected performanceparameters. Samples of each fiber type were weighed out and then blendedusing a small carding drum, approximately 12 cm wide by approximately 15cm in diameter. Intimately blended fiber strands, approximately 5 cmlong, were made for the flame test. Sample buttons, approximately 6.5 cmin diameter, were made out of the blended fibers for the oven screeningtests.

Table 1 below shows the concentration of FR fiber, FR-Thermally ShrinkResistant (TSR) fiber, Comfort Fiber and Structural fiber. Sample Acomprised 20%, by weight, FR-TSR fiber, and Sample B contained no FR-TSRfiber.

TABLE 1 Fiber Screening Blend FR FR FR-TSR Comfort Structural SampleProtex-C Protex-M PyroTex Tencel G-100 Kevlar A 50 20 20 10 B 50 35 15

The fiber strands were evaluated in a flame test by igniting the strandswith a lab Bunsen burner, and then recording the time the flame remainedafter removing the ignition source. In addition the time the samplesglowed after removal of the ignition source was recorded. Finally, theweight of the sample was measured before and after the flame test and apercent weight loss was calculated.

TABLE 2 Fiber Screening Flame Test Total seconds Flame Flame 2 sec.Afterflame Afterglow Weight Weight % weight Sample flame seconds secondsbefore after loss A 120 none none 0.5 0.37 26% B 120 none none 0.5 0.3334%

Sample A with the FT-TSR fiber had a much lower flame % weight loss, at26%, compared to Sample B.

The button samples were placed in a 500° F. oven for 5 minutes todetermine shrinkage and weight loss.

TABLE 3 Fiber Screening Oven Testing 500 degree F. Oven Fiber Oven for 5min % button Sam- Weight weight weight diameter diameter Shrinkage plebefore after loss cm before cm after percent A 0.5 0.32 36% 6.5 5 23% B0.5 0.3 40% 6.5 5 23%

Sample A with the FT-TSR fiber had a much lower oven weight loss % thanSample B, and the same percent shrinkage as Sample B.

Four different fiber blends, Fiber Blend 1 through 4 as shown in Table4, were prepared as described herein. Comparative Fiber 1 was preparedto demonstrate the improved properties of the fiber blend describedherein. Initial tests suggested that Fiber Blend 4 provided the bestcombination of properties including thermal properties, shrinkresistance properties and comfort, or moisture management properties.FIGS. 1 through 4 graphically show the Fiber Blends 1 through 4,respectively. FIG. 5 graphically shows the fiber blend of Comparativefiber 1. Fiber Blend 1 is comprised of 30% by weight comfort component,Lyocell which is hydrophilic, 20% by weight, thermally shrink resistantfiber component, acrylic FR, which is also hydrophilic, and 5% by weightstructural component, para aramid, also hydrophilic. Therefore, FiberBlend 1 was comprised of 50% by weight hydrophilic fiber component and50% by weight hydrophobic component. Fiber Blend 2 was comprised of 45%hydrophilic component, and 55% hydrophobic component, as shown in FIG.2. Fiber Blend 3 was comprised of 40% hydrophilic component, and 60%hydrophobic component, as shown in FIG. 3. Fiber Blend 4 is comprised of35% hydrophilic component, and 65% hydrophobic component, as shown inFIG. 4. Comparative Fiber 1 however, is comprised of 75% hydrophobiccomponent and only 15% hydrophilic component.

TABLE 4 Fiber Blends: Weight Percent of Fiber Components. ThermallyShrink Resistant FR Fiber (TSR) Comfort Structural Component ComponentComponent Component Fiber Blend 1 45% 20% 30% 5% Fiber Blend 2 50% 15%30% 5% Fiber Blend 3 55% 20% 15% 10% Fiber Blend 4 55% 20% 20% 5%Comparative 80% 0% 15% 5% Fiber 1

Table 5, below, provides specific details about the types of fibers usedin fiber blends 3 and 4.

TABLE 5 Fiber Details, Fiber Blend 3 Generic % Fabric % Fabric StapleComponent Manufacturer Type Name Blend 3 Blend 4 Denier Length FRKanekacaron Protex C Modacrylic 55 55 1.5 2″ TSR Pyrotex 2.5-50Acrylic-FR 20 20 2.5 2″ Comfort Lenzing Tencel Lyocell 15 15 1.2 2″ G100o Structural DuPont Kevlar Para 10 5 1.5 2″ Aramid

Fiber blends 3 and 4 were made into woven fabrics as described in Table6. After blending, the homogenous fiber mix was then processed throughcarding and drawing. Yarn was formed on Air Jet Spinning equipment tothe specified counts preferably in the range from 13/1 to 15/1.Alternative staple fiber spinning technologies that could be usedinclude ring spinning, compact spinning, DREF spinning and Open Endspinning Fabric was woven to twill construction constructions in therange of 77 to 82 warp count and 43 to 50 weft counts. Fabric designsinclude 2×1 right and left hand twills as well as 3×1 left hand twill.Alternative embodiments may be knit and nonwoven fabrics as well asother woven constructions. The fabrics were scoured according tostandard industry practices and jet dyed to shade. Mocacrylic andPyrotex dye procedures are compatible regarding type of dyes and dyeprocess. All fibers are theoretically dye accepting except for Paraaramid. For dark shades, a producer dyed black Para aramid would beused. For light shades (khaki) standard Para aramid could be used.Fabric was finished with an antimicrobial after dyeing. Performancefinishes may be applied at this point including permanent press or stainresistance.

TABLE 6 Fabric Constructions Fiber Yarn Weight Blend Weave CountConstruction oz./yd2 Fabric 1 3 2 × 1R 13 77 × 50 8.2 Fabric 2 3 3 × 1L14 77 × 48 7.4 Fabric 3 3 2 × 1L 15 82 × 43 6.9 Fabric 4 4 2 × 1R 26/277 × 50 8.4

Test Methods

The following test methods were used to evaluate exemplary embodiments,unless otherwise noted.

Water Weight Gain and Water Release Rate (WRR) Test Method

The water release rate (WRR) of materials made according to the presentinvention as well as comparative materials were measured according toAATCC MM TS-05A.

Gravimetric Drying Test Method.

The drying times of materials made according to the present invention aswell as comparative materials were measured according to AATCC MMTS-05A.

For a typical test, four 2.5×2.5 inch square specimens were used. Two ofthe specimens were the “control” (reference) fabric and two were the“test” fabric of interest. Samples were conditioned in the conditioningroom at temperature of 70° F. and 55% relative humidity for at least 4hours prior to test. The samples were weighed using a laboratorybalance, accurate to 0.0001 g. Then 10 mL of distilled water was placedinto a 25 ml beaker. Samples were submerge, one specimen in the beakerfor 5-10 minutes, making certain that the specimen was completelysubmerged under the water to insure complete wetting. Samples wereremoved from the beaker and sandwich between two pieces of unused AATCCblotter paper and passed through a wringer. The samples were leftsandwiched in the wet blotters

A vertical specimen stand was placed on a balance and the weight wastarred. The blotted test specimen was hung from the vertical stand. Theweight of the test specimen was recorded. The balance was coupled to adata acquisition system comprising LabView software. Weight readingswere automatically recorded every 15 seconds by the computer. The testwas complete once the specimen weight had reached a designated stoppingmoisture level vs. the dry conditioned weight. The stopping moisturelevel was approximately 0.5% to 1%. The test was ended by stopping dataacquisition in LabView. The data file was saved for that specimen.

Calculation and Interpretation

Total drying time is the time it takes the specimen to reach thestopping weight.

Total water release rate (“WRR”, g/min) was calculated as follows:

Total WRR=(wet specimen weight−ending specimen weight)/(total dryingtime)

WRR, total (%) is calculated from the respective total WRR values asfollows:

WRR_(total)=100×(WRR_(test)−WRR_(control))/WRR_(control)

“Comfort Zone” drying time (min) is the time it takes the specimen'smoisture content to decrease from 15% to 0.5% (polyester) or 20% toapproximately 1%.

“Comfort Zone” WRR (g/min) was calculated as follows:

Active WRR=(wet specimen weight−ending specimen weight)/(“active” dryingtime)

WRR(Comfort Zone) was calculated in the same manner as for WRR(total)except using test and control WRR(Comfort Zone) values.

Vertical Wicking (AATCC MM TS-06 Vertical Wicking-Modified-HanesProtocol):

The purpose of this test is to determine the rate at which water willwick vertically up test specimens suspended in water. A 500 mlErlenmeyer flasks was filled with 200 mL colored water. Samples offabric six inches by one inch were cut for evaluation. The longdirection was cut parallel with the warp direction of the woven fabricsamples and parallel with the wale direction of the knitted fabricsamples. A straight pin was pierced through one end, approximately 0.25inch from the top of sample, and the sample was lowered into the flaskand supported by the pin across the top of the flask. After one minute,the sample was removed from the flask and the distance the water hadwicked up the sample, as indicated by the change in color of the sample,as recorded. The sample was then placed back into the flask and removedafter a period of three minutes, five minutes and every additional fiveminute interval thereafter until the water wicked a distance of sixinches or one hour had elapsed. The time it took for the water to wickup the sample six inches or the distance the water level wicked up thesample after one hour was reported.

Dry & Wet Abrasion Resistance (ASTM D 4966):

Test Method followed was Modified ASTM D 4966—Abrasion Resistance ofTextile Fabrics (Martindale Abrasion Tester Method) 2. Abradant used was600 ultrafine grit 3M (9084NA) sandpaper and the fabric was subject to 9kPa of pressure. For wet abrasion test, fabrics were soaked in water andpassed through padding mangle at 0.05 MPa pressure. A, Laboratory DyePadder available from Lab-Pro, Dorfstrasse 19 Germany, was used for thepadding to remove excess water from the samples.

Heat and Thermal Shrinkage Resistance NFPA 2112-0.7 Ed, Section 8.4

This test determines the performance of fabrics when exposed to heat inan oven at 500° F. Observations of ignition, melting, dripping, orseparation are recorded and reported for each specimen. The percentchange in the width and length direction of the specimen is calculated.Results are recorded and reported as the average of three specimens.

Specimen marking and measurements are conducted in accordance with theprocedure specified in AATCC 135 Dimensional Change in Automatic HomeLaundering of Fabrics. The specimen is suspended by metal hooks at thetop and centered in an oven so that the entire specimen is not less than50 mm from any oven surface or other specimen, and air is parallel tothe plane of the material. The specimen, mounted as specified, wasexposed in the test oven for 5 minutes at 500° F.

Flame Resistance of Textiles (Vertical)

This test method determines the response of textiles to a standardignition source, deriving measurement values for after-flame time,afterglow time, and char length. The vertical flame resistance, asdetermined by this test method, only relates to a specified flameexposure and application time. This test method maintains the specimenin a static, draft-free, vertical position and does not involve movementexcept that resulting from the exposure. Test Method D6413 has beenadopted from Federal Test Standard No. 191A method 5903.1, which hasbeen used for many years in acceptance testing.

Samples were cut from fabric to be tested and were mounted in a framethat was hung vertically from inside the flame chamber. A controlledflame was exposed to the sample for a specified period of time.After-flame time, the length of time the material continued to burnafter removal of the burner, and after-glow time, the length of time thematerial glowed after the flame was extinguished, were both recorded.Finally, the specimen was torn by use of weights and the char length,the distance from the edge of the fabric that was exposed to the flameto the end of the area affected by the flame, was measured.

Flash Fire Test Results: Manikin Test

ASTM F1930-99 is a full-scale mannequin test designed to test fabrics incompleted garment form in a simulated flash fire. A mannequin, with upto 122 heat sensors spaced around its body, is dressed in the testgarment, and then exposed to a flash fire for a pre-determined length oftime. Tests are usually conducted at heat energies of 1.8-2 cal/cm²sec,and for durations of 2.5 to 5.0 seconds for single layer garments.Results are reported in percentage of body burn. For consistency in dataand accuracy of comparison, the test method defines a standard garmentsize and configuration that must be used on each test.

Arc Rating: ASTM F 1959/F 1959M—06ae1—Standard Test Method forDetermining the Arc Rating of Materials for Clothing

This test method was used to measure the arc rating of materialsintended for use as flame resistant clothing for workers exposed toelectric arcs that would generate heat flux rates from 84 to 120 kW/m2(2 to 600 cal/cm2 s). This test method will measure the arc rating ofmaterials which meet the following requirements: less than 150 mm [6in.] char length and less than 2 s after flame when tested in accordancewith Test Method D 6413A.

Test Results:

TABLE 7 Vertical Wicking, Water Weight Gain and WRR results Comfort ZoneVertical Wicking Water WRR (20%-3% No. Of Length in 5 Weight Moisture)ITEM Components Launderings minutes (cm) Gain (%) %/min Fabric 2 55%Modacylic 0 Wash 47.9 0.41 20% TSR-FR 5 Wash 52.1 0.28 15% Tencel 10Wash  53 0.42 10% Para-Aramid Fabric 3 55% Modacylic 0 Wash 45.1 0.4420% TSR-FR 5 Wash 9.6 48.3 0.3 15% Tencel 10 Wash  49 0.4 10%Para-Aramid Bulwark 65% Modacrylic/ 0 Wash 25.1 0.66 Protera FR (6.5Oz/Sq Yd) 33% Nomex/ 5 Wash 8.5 27.7 0.62 2% Antistat 10 Wash  28.5 0.75Carhartt FR 88% Cotton 0 Wash 35.3 0.42 Indura Ultrasoft (7.0 Oz/Sq Yd)12% Nylon 5 Wash 5.1 37.4 0.37 10 Wash  37.9 0.36 Cool Touch FR 48%Modacrylic 0 Wash 33.7 0.5 Tecasafe Plus (7.0 Oz/Sq Yd) 37% Lyocell 5Wash 8.2 37.3 0.46 15% Para-Aramid 10 Wash  37.2 0.46

The inventive Fabric 3 showed better vertical wicking performance thanthe comparative fabrics. The vertical wicking weight of the inventivefabric was almost double that of the Carhart FT comparative sample.Inventive Fabric 2 and 3, as described herein, both had much higherinitial, 0 wash, weight gain than comparative FR fabrics, showing thatthe inventive fabric has a much higher capacity for adsorbing water. Inaddition, the fabrics made with the fiber blend according to the presentinvention had relatively high WRR release rates after 10 washes. Thisrelatively high WRR coupled with the high water weight gain provides forincrease wicking and removal of sweat.

TABLE 8 Wet and Dry Abrasion Dry Abrasion Wet Abrasion Item/FabricComponents # of Abrasion # of Abrasion Fabric 2 55% Modacylic 4000 150020% TSR-FR 15% Tencel 10% Para-Aramid Bulwark 65% Modacrylic/ 2000 1000Protera FR 33% Nomex/ (6.5 Oz/Dq Yd) 2% Antistat Carhartt FR 88% Cotton4000 2000 Indura Ultrasoft 12% Nylon (7.0 Oz/Sq Yd) Cool Touch FR 48%Modacrylic 4000 2000 Tecasafe Puls 37% Lyocell (7.0 Oz/Sq Yd) 15%Para-Aramid

Fabric 2 performed better in terms of dry & wet abrasion resistance thanBULWARK PROTERA FR, and had relatively equal performance with INDURAULTRASOFT & TECASAFE PLUS FR fabrics. It was surprising that a compositefabric with only 10% abrasion resistant material, para-aramid, couldperform as well as Bulwark's Protera FR, having 33% Nomex, a veryabrasion resistant material.

TABLE 9 Flame Resistance of Textiles (Vertical Flame Test) TestDescription Test Method Requirement Fabric 1 Fabric 2 Fabric 3 FlameResistance NFPA 2112-07 Ed, Section 8.3 As Received Flammability ASTMD6413 (Warp/Fill) Char Length (in) 4.0 in (max) 3.2 × 2.5 3.7 × 2.7 3.8× 2.6 After Flame (sec) 2 sec (max) 0 0 0 Melt/Drip NMND No No NoFlammability after 100 Washes ASTM D6413 (Warp/Fill) Char Length (in)NFPA 2112-07 Ed, 4.0 in (max) 3.9 × 3.4 4.0 × 4.0 4.0 × 3.9 8.1.3 AfterFlame (sec) Wash and Dry 2 sec (max) 0 0 0 Procedure Melt/Drip NMND NoNo No

Fabrics 1 through 3, of the present invention, all meet the flameresistance requirements of NFPA 2112 as shown in Table 9.

TABLE 10 Heat and Thermal Shrinkage Resistance Test Description TestMethod Requirement Fabric 1 Fabric 2 Fabric 3 Comparative 1 ThermalShrinkage NFPA 2112-07 NPFA 1971- Resistance Ed, Section 8.4 07 Sec. 8.6Modified* Warp Direction (Initial) 10% max 5.2 5.3 3.5 Fail FillDirection (Initial) 10% max 4.3 7.1 7.1 Fail After 3 wash/dry cycles -NFPA 2112-07 10% max 4.3 6.4 5.5 Warp Direction Ed, 8.1.3, Wash/DryAfter 3 wash/dry cycles - NFPA 2112-07 10% max 4.7 6.9 6.2 FillDirection Ed, 8.1.3, Wash/Dry

Fabrics 1 through 3, of the present invention, all met the thermalshrink resistance requirements of NFPA 2112 as shown in Table 10.Comparative fabric 1, as described herein, a plain weave fabric that was5.5 oz/yd² failed the shrink test as described in Table 10. Thecomparative fabric sample shrunk and curled to the point where thedimensions after the test could not be measured. The thermal shrinkresistance test shows the surprising value of a blend of FR fibercomponents, and especially a blend of acrylic derivative FR fibercomponents, as described herein. The comparative sample, and the Fabrics1 through 3 all had similar acrylic derivative fiber component, however,only the inventive fabrics, Fabric 1 through 3, passed the thermalshrink resistance test.

TABLE 11 Flash Fire Test Results: Manikin Test Test Description TestMethod Requirement Fabric 1 Fabric 2 Fabric 3 Flash Fire Exposure(Manikin NFPA 2112-07 Ed, 3 second Yes Yes Yes Test) Section 8.5exposure Standard Garment Design ASTM F 1930, Yes Yes Yes 8.3.2 TestGarment after 1 wash cycle ASTM F 1930, 50% max Body 14.75%** 13.93%15.02% NFPA 2112-07 Ed, Burn 8.1.3 Wash/Dry Cycle Undergarments - 4.5 oz(+/−5%) Yes Yes Yes 100% cotton short sleeved crew neck T-shirt andbriefs

Fabrics 1 through 3, of the present invention, all meet the flash fireexposure requirements of NFPA 2112 as shown in Table 11.

TABLE 12 Arc Rating Test Description Test Method Requirement Fabric 1Fabric 2 Fabric 3 Thermal Protective Performance NFPA 2112-07 Ed (TPP)Initialo Spaced Rating Section 8.2 6.0 cal/cm2 (min) 12.58 13.28 11.62Initial Contact Rating Section 8.2 3.0 cal/cm2 (min) 8.01 8.07 7.15After 3 wash/dry cycles Spaced Section 8.2 8.1.3 6.0 cal/cm2 (min) 12.8713.35 12.95 Rating for wash/dry After 3 wash/dry cycles Contact Section8.2 8.1.3 3.0 cal/cm2 (min) 8.67 7.57 7.57 Rating for wash/dry

Fabrics 1 through 3, of the present invention, all meet the thermalprotective performance requirements of NFPA 2112 as shown in Table 12.

TABLE 13 Other Fabric Properties: Test Description Test MethodRequirement Fabric 1 Fabric 2 Fabric 3 Tensile Strength (1506) ASTM D5034 (Grab 40 × 40 175 × 102 167 × 83  158 × 74  Method) Tear Strength(1506) ASTM D1424 4 × 4 8.9 × 6.5 10.1 × 9.0  8.8 × 6.4 (Elmendorf)Dimensional Stability (% max) AATCC-135, 3, IV, A, 3   6.7 × 2.3***  6.5 × 4.7*** 4.8 × 5.4 iii (5 cycles) Dimensional Stability (% max)AATCC-135, 1, V, A, 7.7 × 2.6   7.0 × 5.2***   6.2 × 6.0*** iii (5cycles) Colorfastness to Laundering AATCC-61 (3 3 3 3 2 to 3 cycles)Colorfastness to Dry Cleaning AATCC 132 3 3 to 4 4 4 Colorfastness toCrocking (dry and AATCC 8 4 to 5 4 to 5 4 to 5 wet) Colorfastness toLight (40 hours) AATCC 16 Opt E 2 to 3 3 to 4 3 Colorfastness toPerspiration AATCC 15 4 4 to 5 3 to 4 pH AATCC 81 8.2 8.2 8.1 SeamEfficiency (%) ASTM D 1683a N/A 45.6 × 77.7 50.4 × 75.6 Seam Slippage,max ASTM D 434 .25″ @ 40 lbf Pass Pass Pass Arc Rating ASTM F 1959 HRCII >8 11 ATPV 10 ATPV 8.2 ATPV

Fabrics 1 through 3, of the present invention, had surprisingly highphysical properties, and were durably dyed as shown in Table 13.

The disclosures of each patent, patent application, and publicationcited or described in this document are hereby incorporated herein byreference, in their entirety.

Those skilled in the art will appreciate that numerous changes andmodifications can be made to the preferred embodiments of the inventionand that such changes and modifications can be made without departingfrom the spirit of the invention. It is, therefore, intended that theappended claims cover all such equivalent variations as fall within thetrue spirit and scope of the invention.

1. A fiber blend, comprising: about 30-80%, by weight, of an acrylicderivative FR fiber component comprising: a first hydrophobic FRmodacrylic fiber, and a second hydrophilic thermally shrink resistantacrylic FR fiber that is at a level of at least about 10% by weight,based on the total weight of the fiber blend.
 2. The fiber blend ofclaim 1, further comprising: about 10-35%, by weight, based on the totalweight of the fiber blend, of a comfort fiber component comprising atleast one material selected from the group consisting of cotton,cellulose, cellulose derivatives, wool, and combinations thereof andabout 5-25%, by weight, based on the total weight of the fiber blend, ofat least one structural fiber component comprising at least one polymerselected from the group consisting of aramid fiber, melamine fiber,nylon fiber, structural carbon fiber, polyacrylonitrile fibers andcombinations thereof.
 3. The fiber blend of claim 1, further comprisingabout 0.1 to 3% by weight, based on the total weight of the fiber blend,of at least one antistatic fiber.
 4. The fiber blend of claim 1, whereinthe acrylic derivative FR fiber component consists essentially of: thefirst hydrophobic FR modacrylic fiber; and the second hydrophilicthermally shrink resistant acrylic FR fiber that is present at a levelof at least about 10% by weight, based on the total weight of the fiberblend.
 5. The fiber blend of claim 1, wherein the acrylic derivative FRfiber component consists essentially of inherently flame-resistantfibers.
 6. The fiber blend of claim 1, wherein the hydrophilic thermallyshrink resistant acrylic FR fiber consists essentially of inherentlyflame-resistant fibers.
 7. The fiber blend of claim 1, wherein thehydrophilic thermally shrink resistant FR fiber is a dye acceptingfiber.
 8. The fiber blend of claim 1, wherein the hydrophilic thermallyshrink resistant FR fiber is a high LOI fiber, having an LOI of at least38.
 9. The fiber blend of claim 1, wherein the acrylic derivative FRfiber component comprises up to about 50% by weight, based on the weightof the acrylic FR fiber component, of a thermally shrink resistantacrylic FR fiber component.
 10. The fiber blend of claim 1, wherein theacrylic derivative FR fiber component comprises about 20% by weight,based on the total weight of the fiber blend, of a thermally shrinkresistant acrylic FR fiber component.
 11. The fiber blend of claim 1,wherein the acrylic FR fiber component comprises no more than about 30%by weight of the total fiber blend, of the hydrophilic thermally shrinkresistant acrylic FR fiber component. 12-13. (canceled)
 14. The fiberblend of claim 1, wherein said first hydrophobic FR modacrylic fiberconsists essentially of antimony containing hydrophobic modacrylic fiberand the second hydrophilic thermally shrink resistant acrylic FR fiberconsists essentially of antimony and halogen free acrylic FR fiber. 15.The fiber blend of claim 1, wherein said acrylic derivative FR fibercomponent is present at a level of about 40-80%, by weight, based on thetotal weight of the fiber blend.
 16. (canceled)
 17. The fiber blend ofclaim 2, wherein the comfort fiber component is hydrophilic.
 18. Thefiber blend of claim 2, wherein the comfort fiber component consistsessentially of cellulose derivatives.
 19. The fiber blend of claim 2,wherein said comfort fiber component is cotton.
 20. The fiber blend ofclaim 2, wherein said comfort fiber component is present at a level ofabout 10-25%, by weight, based on the total weight of the fiber blend.21. (canceled)
 22. The fiber blend of claim 2, wherein said structuralfiber component is aramid fiber.
 23. (canceled)
 24. The fiber blend ofclaim 2, wherein said structural fiber component is present at a levelof about 10-20%, by weight, based on the total weight of the fiberblend.
 25. (canceled)
 26. The fiber blend of claim 2, wherein said FRfiber component is acrylic derivative fiber or a combinations thereof;wherein said comfort fiber component is cellulose or a cellulosederivative, or a combinations thereof; and wherein said structural fibercomponent is aramid fiber, carbon or PAN, nylon fiber, or a combinationthereof.
 27. A fabric comprising a fiber blend, comprising about 30-80%by weight, based on the total weight of the fiber blend, of an acrylicderivative FR fiber component comprising: a first hydrophobic FRmodacrylic fiber; and a second hydrophilic thermally shrink resistantacrylic FR fiber that is present at a level of at least about 10% byweight, based on the total weight of the fiber blend.
 28. The fabric ofclaim 27, further comprising: about 10-35%, by weight, based on thetotal weight of the fiber blend, of a comfort fiber component comprisingat least one material selected from the group consisting of cotton,cellulose, cellulose derivatives, wool, and combinations thereof; andabout 5-25%, by weight, based on the total weight of the fiber blend, ofat least one structural fiber component comprising at least one polymerselected from the group consisting of aramid fiber, melamine fiber,nylon fiber, structural carbon fiber, polyacrylonitrile fibers andcombinations thereof. 29-37. (canceled)
 38. A fiber blend, comprising:about 30-80%, by weight, of a FR fiber component comprising: a first FRfiber component, comprising at least one fiber selected from the groupconsisting of modacrylic, fluoropolymer, polybenzimidazole (PBI), andcopolymers thereof, and combinations thereof that is hydrophobic, and asecond thermally shrink resistant FR fiber that is present at a level ofat least 10% by weight of the total fiber blend; about 10-35%, byweight, based on the total weight of the fiber blend, of a comfort fibercomponent comprising at least one material selected from the groupconsisting of cellulose, cellulose derivatives, wool, and combinationsthereof; and about 5-25%, by weight, based on the total weight of thefiber blend, of at least one structural fiber component comprising atleast one polymer selected from the group consisting of aramid fiber,melamine fiber, nylon fiber, structural carbon fiber, polyacrylonitrilefibers and combinations thereof.
 39. The fiber blend of claim 38,wherein the first FR fiber component consists essentially of modacrylicfiber.
 40. The fiber blend of claim 38, wherein the second thermallyshrink resistant FR fiber consists essentially of acrylic FR fiber. 41.The fiber blend of claim 38, further comprising about 0.1 to 3% byweight, based on the total weight of the fiber blend, of at least oneantistatic fiber.
 42. The fiber blend of claim 38, wherein the FR fibercomponent consists essentially of: a first hydrophobic FR modacrylicfiber; and a second hydrophilic thermally shrink resistant acrylic FRfiber that is present at a level at least about 10% by weight, based onthe total weight of the fiber blend.
 43. The fiber blend of claim 38,wherein the FR fiber component consists essentially of inherentlyflame-resistant fibers.
 44. The fiber blend of claim 38, wherein thethermally shrink resistant FR fiber consists essentially of inherentlyflame-resistant fibers.
 45. The fiber blend of claim 38, wherein thethermally shrink resistant FR fiber is a dye accepting fiber.
 46. Thefiber blend of claim 38, wherein the thermally shrink resistant FR fiberis a high LOI fiber, having an LOI of at least
 38. 47. The fiber blendof claim 38, wherein the FR fiber component comprises up to about 50% byweight, based on the weight of the FR fiber component, of a thermallyshrink resistant FR fiber component. 48-51. (canceled)
 52. The fiberblend of claim 38, wherein said first FR fiber component consistsessentially of antimony containing hydrophobic modacrylic fiber and thesecond FR fiber component consists essentially of antimony and halogenfree acrylic FR fiber, that is hydrophilic.
 53. The fiber blend of claim38, wherein said FR fiber component is present at about 40-80%, byweight, based on the total weight of the fiber blend.
 54. (canceled) 55.The fiber blend of claim 38, wherein the comfort fiber component ishydrophilic.
 56. The fiber blend of claim 38, wherein comfort fibercomponent consists essentially of cellulose derivatives.
 57. The fiberblend of claim 38, wherein said comfort fiber component is cotton. 58.The fiber blend of claim 38, wherein said comfort fiber component ispresent at about 10-25%, by weight, based on the total weight of thefiber blend.
 59. (canceled)
 60. The fiber blend of claim 38, whereinsaid structural fiber component is aramid fiber.
 61. (canceled)
 62. Thefiber blend of claim 38, wherein said structural fiber component ispresent at about 10-20%, by weight, based on the total weight of thefiber blend.
 63. The fiber blend of claim 38, wherein said structuralfiber component is present at about 10-15%, by weight, based on thetotal weight of the fiber blend.
 64. (canceled)
 65. A fabric comprising:about 30-80%, by weight, of a FR fiber component comprising: a first FRfiber component, comprising at least one fiber selected from the groupconsisting of modacrylic, fluoropolymer, polybenzimidazole (PBI), andcopolymers thereof, and combinations thereof that is hydrophobic, and asecond thermally shrink resistant FR fiber that is present at a level ofat least 10% by weight of the total fiber blend; about 10-35%, byweight, based on the total weight of the fiber blend, of a comfort fibercomponent comprising at least one material selected from the groupconsisting of cellulose, cellulose derivatives, wool, and combinationsthereof; and about 5-25%, by weight, based on the total weight of thefiber blend, of at least one structural fiber component comprising atleast one polymer selected from the group consisting of aramid fiber,melamine fiber, nylon fiber, structural carbon fiber, polyacrylonitrilefibers and combinations thereof. 66-74. (canceled)
 75. A fiber blend,comprising: about 55%, by weight, based on the total weight of the fiberblend, of a FR fiber component that is not thermally shrink resistant;about 20%, by weight, based on the total weight of the fiber blend, of athermally shrink resistant FR fiber component; about 15%, by weight,based on the total weight of the fiber blend, of a comfort fiber; andabout 10%, by weight, of para-aramid fiber structural fiber component.76. A fiber blend, comprising: about 55%, by weight, based on the totalweight of the fiber blend, of modacrylic and 20% by weight, based on thetotal weight of the fiber blend, of acrylic FR fiber; about 15%, byweight, based on the total weight of the fiber blend, of cotton; andabout 10%, by weight, based on the total weight of the fiber blend, ofpara-aramid fiber.
 77. A yarn comprising the fiber blend of claim 2,wherein said FR fiber component, said comfort fiber component, and saidstructural fiber component are intimately blended.
 78. A fabriccomprising the yarn of claim
 77. 79. A fabric of claim 78, wherein thefabric is a twill weave.
 80. A fabric of claim 78, wherein the fabric isa knit. 81-85. (canceled)
 86. The fabric of claim 78, wherein saidfabric has a basis weight of less than about 8.0 ounces/square yard(OPSY).
 87. (canceled)
 88. The fabric of claim 78, wherein said fabricis woven.
 89. (canceled)
 90. A garment comprising the fabric of claim78.
 91. A garment of claim 90, wherein said fabric forms at least oneouter portion of said garment.
 92. A garment of claim 90, wherein saidgarment is outerwear.
 93. A garment of claim 90, wherein said outerwearis a coat, coverall, overall, shirt, or pants.
 94. (canceled)
 95. A yarncomprising the fiber blend of claim 38, wherein said FR fiber component,said comfort fiber component and said structural fiber component areintimately blended.
 96. A fabric comprising the yarn of claim
 95. 97.The fabric of claim 96, wherein the fabric is a twill weave.
 98. Thefabric of claim 96, wherein the fabric is a knit.
 99. The fabric ofclaim 96, wherein said fabric is woven.
 100. A garment comprising thefabric of claim 96.